Embedded Files
Written By: Daniel Asante
Current Design
Current Design
The figure to the left is the current CAD model of ArcticSat as of April 2025. ArcticSat features two deployable solar arrays with each solar array having 6 solar cells. The payload consist of a passive cylindrical radiometer reflector as well as a feed which is at an angle of 45° and 91 mm away from the reflector. This geometric relationship is essential for the operation of the payload in order to achieve the maximum possible gain with respect to the size of the antenna.
A key design update has been implemented in the ArcticSat structure to accommodate the requirements of the new launch provider, Exolaunch. Specifically, the height of the solar wing hinges has been increased to ensure a 25 mm clearance between the rear surface of the solar wing back plate and the satellite shell.
This modification aligns with the Exopod NOVA deployer interface requirements, which specify a maximum allowable clearance of 25 mm between the CubeSat structure and the deployer wall, as outlined in the Exolaunch User Manual.
The following external components utilize this extra volume provided by the Exopod NOVA deployer:
1x Reaction Wheel
2x S-band Patch Antennas
1x Magnetorquer Rod (Z-axis)
1x Remove-Before-Flight (RBF) Pin
.
The figure above illustrates the -Z face of ArcticSat, which accommodates both the GNSS antenna and the coupler. A key design revision on this face involves the relocation and modification of the separation switches.
Originally, plunger-style separation switches were placed on this face. However, due to space constraints introduced by the integration of the coupler—which occupies a significant portion of the -Z face—there was insufficient clearance for proper installation and operation of the plunger switches.
To address this limitation, the design was updated to use roller-style separation switches, which are now mounted directly on the CubeSat rails. This modification ensures reliable deployment interface functionality while maintaining compliance with deployment requirements and preserving structural compatibility.
ArcticSat Coordinate System as per the Exopod NOVA deployer
ArticSat Closed Configuration [-Y FACE]
ArcticSat Closed Configuration [ISOMETRIC]
Model Philosophy
Model Philosophy
Four distinct models will be made of ArcticSat's structure: a CAD model, a 3D printed breadboard model (BM), an engineering model (EM), and a flight model (FM). The CAD model will first be created in Phase A, and will be updated continuously as development of the satellite progresses. This model will be used for many verification activities, specifically those which are verified by design and analysis via simulation. The BM will be used primarily as a design for manufacturing and assembly check in Phases A, B, and C. The model can be rapidly and inexpensively produced when major design changes are made to test whether the satellite still fits together. Experience building the BM will be used to develop assembly procedures for the CubeSat. In Phase C, a detailed EM will be produced. This will be used to test manufacturing quality, fitment, and the functionality of deployable components, and to refine assembly procedures. Finally, an FM structure will be manufactured in Phase D. This model will be used for the completed satellite when it is assembled for space.
Structural Block Diagrams
Structural Block Diagrams
ArcticSat's structure will provide mounting, protection, and deployment to all other components of the CubeSat. A block diagram describing the various functions of this structure can been seen below.
ArcticSat structure system block diagram.
In addition to the system block diagram above, it is beneficial to see the functions of the structure. The following block diagram outlines the three main functions of the structure—mounting, deploying, and protecting—and how they interact with the structure and other functions.
ArcticSat structure functional block diagram.
Shell and Rail Structure
Shell and Rail Structure
ArcticSat's shells are based on the general structure design shell shown in the figure below.
The core of the CubeSat's structure is made of 1/2U 6061-T6 aluminum shells, which form 1U modules. These shells start in a mass-manufacturable 'blank' form, with only key features like standard avionics board mounting holes, integrated board standoffs, and harnessing pass-throughs. These blank shells are modified after initial manufacturing to suit the needs of the hardware in each 1U module. For example, the shells in the ADCS module receive additional holes to mount the reaction wheel and magnetorquers. During the AIT phase, each 1U module can be moved and tested on its own. This allows for more efficient parallel AIT work to be performed, such as payload antenna testing at the University of Manitoba campus occurring at the same time as S-band communications testing at Magellan Aerospace's ASIF across the city.
To assemble the full primary structure, the three 1U modules are stacked, and continuous 3U-long corner rails are bolted to the four corners of each module. These rails are made of hard anodized 6061 aluminum, and interface with the CubeSat dispenser. The design of these rails is almost completely carried over from Iris, though with some changes to cut-outs for the payload. This structure is designed to work with the ExoPOD NOVA deployer.
General Structure Design Shell
Shell and Rail rendering
Structural Layout
Structural Layout
ArcticSat's structural layout is driven by the storage and deployment of the payload antenna. The antenna has very specific geometry which must be achieved when deployed. This means that the stowed antenna takes up a large amount of satellite's internals. The image to the right shows the internal layout of the satellite. Note that the diagrams are not to scale, and the payload antenna only illustrates its location, not its relative size or shape.
The top two modules contain two subsystems each. These subsystems are grouped based on the volume of their components, and to maintain efficient harnessing. The bottom module contains the payload antenna when it is stowed, and its HDRM. The middle module contains the CDH and ADCS hardware.
Finally, the top module contains the power control board, the battery pack and its heater, and the communications transceiver with the tuna can accommodating the Coupler and the GNSS Antenna.
Structural Layout
Mass Budget
Mass Budget
The table below details the mass budget for ArcticSat. The budget is broken down by components, or entire subsystems when higher resolution is not needed. The main materials of components are listed for context when they are available. A mass estimate is given, and a decimal margin is applied on top of the estimate for safety. These margins were selected based on the confidence of the estimation, and the likelihood of future design changes. The subtotal column shows the mass with margin applied and the margin column shows the mass without margin applied. Currently ArcticSat is well within mass the budget as the max mass for a 3U CubeSat per the Exopod NOVA user manual is 7 Kg.
Mass Budget
Deployables
Deployables
Solar wings will need to be deployed from the sides of ArcticSat in order to generate sufficient power for operations. Like Iris, the solar wings will use spring loaded hinges and an HDRM [Burn Wire] to deploy.
The same methods and plan is being be used for the payload antenna. The feed of the payload antenna hinges into its module first. The feed arm is angled to provide both the correct view of the reflector, and compact stowing. The reflector then rotates over top of the stowed feed. During deployment, the solar wings are released first, followed by the payload reflector, and then the feed.
Deployment Model Philosophy
Deployment Model Philosophy
Simulation Model
Simulation Model
Develop preliminary CAD model of solar wings and payload antenna in Phase A
Update CAD model in Phases B and C
Breadboard/Prototype Model
Breadboard/Prototype Model
Build prototypes of all deployment mechanisms in Phase B
Test function of prototypes in Phases B and C
Engineering Model
Engineering Model
Build engineering models of deployables in Phase C after prototype tests
Test function of engineering models in Phase C
Flight Model
Flight Model
Build and test flightworthy solar wings and payload antenna in Phases C and D
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